Core Skills Analysis
Math
- Applied proportional reasoning to scale the plate dimensions for the bike, converting design measurements into printable size.
- Used geometry formulas to calculate area, perimeter, and needed curvature to fit the bike frame accurately.
- Set up algebraic equations to estimate filament volume and cost based on layer height and infill density.
- Converted between metric and imperial units (mm ↔ inches) to verify printer settings and final product dimensions.
Science
- Followed the engineering design process: define the need, brainstorm, prototype in Fusion 360, test, and iterate.
- Investigated material properties of PLA filament—melting point, tensile strength, and biodegradability—to choose appropriate print settings.
- Applied concepts of forces and stress, ensuring the plate can withstand vibrations and loads during a race.
- Considered energy consumption of the 3‑D printer and discussed sustainability of additive manufacturing versus traditional methods.
Tips
To deepen understanding, have the student create a detailed bill of materials and calculate total project cost, then compare it to a commercially‑available plate. Next, challenge them to redesign the plate for a different bike size, documenting how the scaling changes affect material use and strength. Conduct a load‑test experiment by attaching incremental weights to the printed plate and recording when deformation occurs, linking the data back to the stress calculations performed earlier. Finally, integrate a reflection journal where they connect the math calculations, engineering decisions, and real‑world performance outcomes, reinforcing both analytical and creative thinking.
Book Recommendations
- The Way Things Work by David Macaulay: Illustrated explanations of mechanical principles that help students see how everyday objects, like bike parts, function.
- Make: 3D Printing by Anna Kaziunas France: A hands‑on guide to designing, printing, and troubleshooting 3‑D projects, perfect for teen makers.
- Engineering: A Very Short Introduction by David Blockley: Concise overview of engineering concepts, including design cycles, material science, and sustainability.
Learning Standards
- CCSS.MATH.CONTENT.HSG.GPE.1 – Understand congruence and similarity using physical models.
- CCSS.MATH.CONTENT.HSG.MG.A.1 – Solve real‑world problems involving measurement and conversion.
- CCSS.MATH.CONTENT.HSF.IF.C.8 – Use functions to model relationships between variables (e.g., filament use vs. infill).
- NGSS HS-ETS1-2 – Design a solution to a problem by evaluating competing solutions based on criteria.
- NGSS HS-ETS1-3 – Evaluate a design solution against constraints and criteria.
- NGSS HS-PS3-3 – Design, build, and refine a device that converts energy from one form to another (considering printer energy use).
Try This Next
- Worksheet: Calculate filament volume, cost, and waste for three different infill percentages.
- Quiz: Identify geometry terms (radius, chord, tangent) used in the plate’s CAD model.
- Drawing task: Sketch two alternative plate shapes that could improve aerodynamics and label required dimensions.
- Experiment: Attach sandbags incrementally to the printed plate and record the weight at which it bends or breaks.